Stiff fabric composite and method of making

Abstract

A woven or non-woven fibrous material has a substrate formed of first and second thermoplastic fibers. The fabric is passed through an oven at a temperature sufficient to melt the first fibers thereby fusing at least some of the first fibers and second fibers one to the other. The second fibers retain their discrete definition within the composite whereby the composite is provided such that, when cut for use, for example, to form a slat of a vertical blind or a wall panel, the composite retains its shape. A foam backing is provided and cured in the oven simultaneously with the melting of the first fibers.

What is claimed is: 
     
       1. A method of forming a stiff fabric having stitch through warp yarns and a substrate comprising the steps of: on a knitting machine, (a) providing a non-woven substrate for movement in the machine direction formed of first and second different fibers with said first fibers formed of thermoplastic material having a predetermined melting temperature, and (b) stitching the warp yarns and substrate each to the other, and   thereafter, heating the fabric to a temperature to fuse said first fibers with said second fibers of the substrate to provide a predetermined stiffness to the fabric while simultaneously retaining the definition of said second fibers as fibers in said fabric and with stitch underlaps and loops exposed and defined on opposite sides of the stiff fabric.   
     
     
       2. A method of forming a stiff fabric having stitch through warp yarns, a substrate and a foam backing comprising the steps of: on a knitting machine, (a) providing a non-woven substrate for movement in the machine direction formed of first and second different fibers with said first fibers formed of thermoplastic material having a predetermined melting temperature, and (b) stitching the warp yarns and substrate each to the other;   applying a foamed or foamable composition of a polymeric material to one side of said substrate; and   thereafter, heating the fabric, substrate and foamed or foamable composition simultaneously to a temperature to (i) fuse said first fibers with said second fibers of the substrate to provide a predetermined stiffness to the fabric while retaining the definition of said second fibers as fibers in said fabric and (ii) cure the foamed or foamable composition to form a stiff fabric composite with a foam backing.   
     
     
       3. A method according to claim 2 including fusing said first fibers to the warp yarns. 
     
     
       4. A method according to claim 2 wherein the fabric is a warp-knit, weft-inserted fabric, including the steps of, on said knitting machine, laying in weft yarns in the cross-machine direction and stitching the weft yarns and substrate each to the other. 
     
     
       5. A method according to claim 2 including the step of laying in warp yarns on the substrate. 
     
     
       6. A method of forming a stiff fabric composite comprising the steps of: needling a non-woven substrate formed of thermoplastic fibers and a woven material one to the other;   applying a foamed or foamable composition to one side of the substrate;   heating the needled non-woven substrate, woven material and foamed or foamable composition simultaneously to a temperature to (i) fuse at least some of said fibers in said substrate and (ii) cure the foamed or foamable composition to provide a fabric composite with foam backing of predetermined thickness.   
     
     
       7. A method according to claim 6 including the steps of providing a non-woven substrate formed of first and second thermoplastic fibers wherein said first fiber has a melting temperature lower than the melting temperature of said second fiber and the step of heating includes melting at least some of the first fibers without substantial melting of the second fibers such that some of the first fibers are fused with the second fibers. 
     
     
       8. A method according to claim 6 including heating the substrate, woven material and foamed or foamable composition to a temperature to fuse at least some of said fibers in said substrate to said woven material. 
     
     
       9. A method of forming a stiff fabric composite comprising the steps of: fusing only a portion of fibers of a substrate, leaving a remaining portion unfused;   applying an adhesive to a surface of the partially fused substrate;   heating the partially fused substrate with adhesive applied thereto to melt the adhesive; and thereafter adhering a fabric to the substrate with the adhesive forming a bond therebetween.   
     
     
       10. A method according to claim 9 including applying a foamed or foamable composition to the substrate and curing the foamed or foamable composition. 
     
     
       11. A method of forming a stiff fabric composite comprising the steps of: applying an adhesive to one of a substrate having first and second thermoplastic fibers and a fabric;   laminating the substrate and the fabric to one another with the adhesive bonding the substrate and fabric to one another; and   heating the laminated substrate and fabric to a predetermined temperature sufficient to melt said first fibers such that said first fibers are fused with said second fibers in the substrate to provide a composite having a predetermined stiffness, with said second fibers remaining substantially wholly unmelted during heating.   
     
     
       12. A method according to claim 11 including applying a foamed or foamable composition to the substrate and curing the foamed or foamable composition. 
     
     
       13. A method according to claim 12 including curing the foamed or foamable composition simultaneously with fusing said first fibers during heating. 
     
     
       14. A method of forming a stiff fabric composite comprising the steps of: disposing a fusible material between a substrate having first and second thermoplastic fibers and a fabric; and   laminating said substrate, fusible material and fabric to one another by heating said substrate, fusible material and fabric to a predetermined temperature sufficient to melt said first fibers such that said first fibers are fused with said second fibers in said substrate to provide a composite having a predetermined stiffness, with said second fibers remaining substantially wholly unmelted during heating.   
     
     
       15. A method according to claim 14 including applying a foamed or foamable composition to the substrate and curing the foamed or foamable composition. 
     
     
       16. A method according to claim 15 including curing the foamed or foamable composition simultaneously with fusing said first fibers during heating. 
     
     
       17. A method of forming a stiff fabric composite including the steps of: passing a fabric formed of acetate and rayon yarns, a substrate having thermoplastic fibers and a spunbonded polyester through a heat transfer/warp print machine;   heating the fabric to a temperature sufficient to melt certain of the fibers in said substrate for fusing with unmelted fibers in the substrate to provide a composite having a predetermined stiffness with certain fibers remaining substantially wholly unmelted during heating.   
     
     
       18. A method of forming a stiff fabric composite comprising the steps of: needling a non-woven substrate formed of first and second thermoplastic fibers, wherein said first fibers have a melting temperature lower than the melting temperature of said second fibers, and a woven material one to the other; and   heating the needled non-woven fabric and woven fabric to a temperature within a range of 310°-370° F. to melt the first fibers without substantial melting of the second fibers such that the first fibers are fused with the second fibers and to said woven fabric to provide a fabric composite of predetermined stiffness,   the step of heating including passing the needled non-woven fabric and woven fabric through an oven at a speed of about 20-30 yards per minute.   
     
     
       19. A method of forming a stiff fabric composite including the steps of: applying a ground polyester powder to a surface of a non-fusible substrate;   heating the substrate with ground polyester powder applied such that said ground polyester powder obtains a molten state on said substrate;   disposing a fabric on the molten polyester; and   laminating the fabric, polyester and substrate to one another to form the stiff fabric composite.   
     
     
       20. A method according to claim 14 wherein the step of heating includes heating the polyester powder to a temperature within a range of 220°-375° F. and the step of laminating includes passing the fabric, polyester and substrate through the nip of a pair of rolls to press the fabric, polyester and substrate together to achieve a bond between the fabric and substrate.